Ten years ago – not long after we moved into this house – my younger brother and I built a pair of workbenches. I designed a “tall” work bench for standing and a “short” work bench that I could sit at (aka, a desk). The idea was that I’d do electronics or other work at the desk. However, “near woodworking tools” is a pretty lousy place to do soldering , etc. and this ended up just being a place to pile scraps and store my drill press, band saw, and power sander. Unfortunately, to use any of those then, I had to haul it out of the corner and put it on another space. They’re not terribly heavy but none of this was ideal. So I had decided I’d tear out the “low” bench and put rolling tool stands in that space. If I’m going to move these tools out to use them, it should at least be easier to do!
Thursday morning, I just so happened on Facebook to catch that my neighbor posted he was giving away an old rolling stand. It looked perfect so I drove over (two blocks away) to grab it. Pretty quickly though I realized this was for far larger tools than I own.1 I couldn’t even shut the door on the Pilot! Fortunately, Angela was out of town so she didn’t need to park in the garage. Yesterday, I tore out most of that “low” bench in order to be able to park the stand in place. You can see that it took up almost the entire 4′ x 3′ space! Those slanted legs were fine for a very heavy piece of equipment, but my Ryobi band saw and Wen power sander weigh maybe 80 lbs combined. I did need to bend one of the caster mounts such that it was level with the others. This wouldn’t be the last time I got to bend some metal on this thing.
So I knew I wanted to re-tool the stand such that the legs are vertical. I gave it some thought and realized that I could pivot the legs about one out of the three bolts that connect each side of each leg (i.e., two bolts on each leg – one for each connecting side). I had measured out and cut a bottom shelf from the “low” desk’s MDF surface so I had something to align the legs to. Then I could just use my level and speed square to get the leg alignment. I used a white paint marker to mark the four new holes and number each of the points so I could re-attach them (nominally it wouldn’t matter, but it just helps to reduce error when things otherwise don’t align because nothing’s “nominal”).
I used the drill press and my step bit to drill the holes. Drilling steel is significantly more difficult than drilling aluminum (which can be generally cut with woodworking blades or bits). I recently read Adam Savage’s book “Every Tool’s a Hammer” in which he has a chapter titled “Use More Cooling Fluid” and, man, is that every sound advice for cutting steel. I typically call it cutting fluid, but given the amount of smoke I was generating, it was definitely getting hot. Also, unlike aluminum, steel is going to have burs that need to be filed off, even when cutting with a step bit. So I had to clean up each of the sixteen holes drilled.
I got the legs re-assembled and cut a top surface (also cut from the old bench’s MDF surface). I did have to replace a few of the bolts with spoiled threads but I happened to have some spare 1/4″ bolts & nuts. It was at that point that I realized that the surfaces of bent steel that were formerly parallel to the floor were now about 10° out of flat. Enter the 5 lbs sledge. I basically whacked the hell out of the top lip all around until the to surface lay nearly flat. Using some screws through the mount holes then got it nice and level.
The casters are the threaded bolt post type. If you’ve never seen these before, please know that they are the worst. The end of the threaded rod is some weird star thing (no, not a Torx bit) which you cannot hold and just spins with the bolt. So, there’s no real good way to loosen a stuck nut – of which I had two. My design required that these casters come off so that I could use them to also mount the bottom shelf. So, some Liquid Wrench and some vice grips to hold the threaded rod (which messes up the threads some, but wasn’t important as that’s where the shelf now sits), I prevailed.
I finally drilled some holes in the corner of the lower shelf so I could sandwich that shelf with the leg bottom and the caster nut & washer. I had to use the sledge to somewhat flatten out the base of each leg. Otherwise the casters would all be at a tilt towards the center of the cart and it would be miserable to move around. This hammering allowed me to get the nut started on the caster threaded rod. I could then tighten it enough to make the entire thing sturdy again.
So, this was a simple adjustment that took me about five hours of work. I couldn’t be happier with the results, though. It rolls smoothly, is plumb and level, and fits perfectly into a tight area. I may put another shelf into this (I still have plenty of leftover MDF!) so that I can store sander belts, band saw blades, fence, etc. But for a project that I didn’t have to buy a single item for, this is exactly what I needed for this space.
- He has converted on bay of a 3-car garage to a very nice wood shop with nice power tools. [↩]